Failure Mode and Effects Analysis (FMEA)

Used extensively in the automotive, aerospace and nuclear industries, FMEA is a tool that examines potential product or process failures, evaluates the risks and helps determine remedial actions to eliminate the identified problems. The target is to improve efficiency, productivity and availability; in one recent FMEA application, the analysis eliminated rework and scrap costs of £200,000 per year.

The core technique breaks down a system into its component parts and considers the possible failure mechanisms. This can obviously be a very time consuming process, and therefore the skill lies in determining the right level of process, system or component to analyse to add most value. The analysis can be most effectively used during the design stage, however, is equally applicable on existing facilities.

There are various forms of FMEA study, each focusing on different aspects of a plant or process. Examples are Design (DFMEA), Machinery (MFMEA) and Process (PFMEA).

In each case, the FMEA is a methodology for assessing risk and identifying any weaknesses in the functionality of a product or desired outcome of a process so that these can be guarded against.

FMEA methodology encompasses the latest thinking including Robustness linkages.

Depending on the type of study these will include :-

  • Boundary Diagram (DFMEA or MFMEA)
  • Interface Matrix (DFMEA or MFMEA)
  • Function Analysis (DFMEA or MFMEA)
  • Process Flow Diagram (PFMEA)
  • Characteristic Correlation Matrix (PFMEA)
  • Failure Modes
  • Effects of Failure
  • Causes of Failure
  • Prevention Controls
  • Detection Controls
  • Practical application of the Ranking Tables
  • Classifications
  • Establishing Priority
  • Recommended Actions
  • Ongoing maintenance of the FMEA

GHA Livigunn can provide skilled FMEA consultants to manage, assist or participate in your studies. Our consultants have proven track records of reducing wastage and downtime. For more information use the contact page to arrange an appointment.

Our Consultants can also offer complementary study techniques such as Integrated Manufacturing Approach, Measurement System Analysis, Statistical Process Control, Problem Solving including the 8D approach and Problem solving utilising the Delphi 5 Why’s.

If you do not see here the support you require, please contact us , we can still help.